Cast refractory product



Patented Mar. 30, 1948 a UNITED STATES PATENT OFFICE CAST REFRACTORY PRODUCT Theodore E. Field, Louisville, Ky, assignor to Cor-hart Refractories Company, Louisville, Ky., a corporation of Delaware No Drawing. Application October 14, 1940, Serial No. 361,187

1 Claim. (01. B--57) 1 2 In my otherapplication, Se'rial'Number30Q480, can vyield, without rupture, to accommodate the Patent No. 2,271,366, January 2 7, 1942, it was strains produced by cooling. until the time that pointed out that melted and castrefractories the glass phase itself becomes too viscous to perconsisting of zirconia and corundum crystals in mit plastic deformation. It then depends upon a matrix of uncrystallize'd glass were especially 6 the physical properties of this glass plr-iase as to resistant to corrosion molten 'glass. in early whether the further strains are sufficient 'to proattempts to manufacture such refractories from duce cracking.

commercial materials however, no castings free At any rate I have found that cracking can be from cracks could be obtained despite careful prevented by altering the chemical composition, annealing in insulating powder. 10 and, therefore the physical properties, of the glass To manufacture zirconia-corundum-glass rephase alone. This can be done either by adding fractories of the desired typ the usual raw masmall amounts of other ingredients or by selectterials commercially available are bauxite, z-irkite ing possible major ingredients in such a Way as and zircon, specimen analyses of which are given to bring about the desired final composition.

in the following table. Two additions Whose effects are quite powerful Table I Material zro. s10. 1.1.0. relo. 'rio. oao. MgO f 11.0 Mac Zirkite. 76. 7 18. 81 2. 2 70 1:06 26 :05 12 13 Do 76.2 12.51 4.8 4. 39 1.50 .26 .04 18 .09 Doc-.. 84.1 V 4. 62v 2.1 7.06 1.57 .24 10 11 .09

Zircon 64.0 35:00 034 .01 .30 20 .10" 00 .02 Do 63.3 29.12 492 521 2.55 -.22 .08 00 .00 ."Do 50.8. 33.64 p 4.2 -32. 4.50 .37, .07 .02

Bauxite 0.0 5.40 "90. 0 2.12 2. 20 .13 1 10 00 .00 D0.-- 0. 0 6.46% "88. 1 2545 2. 51 .07. .10 .06 D0 0.0 8.05 87.4 2.28 1.97 .13 .07 07 .06

It is seen that in the natural materials both in this respect are soda and dolomite. Another the alkali and the alkaline earth are present in important variable is iron oxide, but control in only small quantities. Since these do not crysthis case would normally be exercised by juditallize out, however, they are all concentrated cious selection of the major raw materials since into the glass phase which further contains all iron oxide is present in significant but variable the silica; saturation amounts of A120: and Z1 02; quantities in all three. and also iron oxide and TiOz which may or may The effect of alkali on cracking is illustrated not reach their saturation values. by the following composition in which soda was I have discovered that the cracking of commeradded to the normal commercial materials, and cial baddeleyite-corundum-glassrefractories uncastings. 4" x 1'2" x 18" were made.

Table II W Per cent 10.8 0.06 67.3 1. 3s 1. 49 1e 0s 05 .09 .14 100 der the usual manufacturing conditions ispn- 50 In this system, a sharp lower innit of 0.6% almarily a function the properties of the glass 'kali exists ro'r-good recovery of this size casting phase and is not importantly dependent upon the under usual manufacturing conditions. Other relative proportions of the two primary crystal melts have shown that an even greater excess of phases, or even upon the amount of the glass soda can be used and in fact is required for phase present. surprising result probably larger sizes of castings. I have round for examindicates that the crystal network first formed, ple that 1.3 to 1.4% No.20 must be added to in- 3 sure the recovery of heavy throat covers for glass furnaces. This excess NazO is not harmful however for the recovery of the smaller blocks. Unfortunately the resistance to corrosion by glass 4 As stated above, I have also found the FezOa content in the casting an important variable and this is illustrated by the cracking of the following compositions.

' Table V V Blocks M616 zro, 510. 11.0. F630: T10, 08.0 MgO m N810 11.0 Cracked Percent N 14.6 10.66 71.0 [384 22 2. .02 .06 12 64 .76 100 o 147 11.88 60.0 .35 2.12 .08 .06 13 so .03 0 P 616.1 0.-06 69.3 I 1.81 2.06-- .13 v.00 00 43 .62 62 Q, 16.1 1.70 68.0 2.0 .16 16 .10 14 47 .61 0

M611 210, 610. 111063610; T101 08.0 MgO R0 K N870 f fif I j I Percent 142 10.32 70.0 .61 2.64 1.41 .99 1.40 .04 00 75 14. 2 10. 62 69. 6 60 2. 53 1. 68 1. 07 2. 66 .00 00 Y 0 16.1 10.07 67.9 1.66 2.36 1.20 .66 1.96 .12 00 88 15.1 11.07 67.3 2.06 2. 66- 1.28 .80 2.08, 06 00 g 0 is significantly lowered as soda is increased. so that soda must be kept as low as is consistent with good recovery of the product.

In the same way, the following compositions illustrate the effect of alkaline earth additions (dolomite), also on 4" x 12" x 18" castings.

In this system it is observed that increasing the F6203 by 1.5% in the casting, drops the minimum alkalilimit for good recoveryby 0.3% of its glass phase concentration) and drops the minimum alkaline earth limit by 0.6%.

Table In Blocks Melt zro. s10. 61.0. 6.0. T10; 080 MgO R0 mo N8 0 Cracked Per cent 19. 8 9. 66 57. 3 1. 38 1. 49 16 O8 6 24 O5 09 100 22. 9 9. 75 63. 2 1. 28 1. 74 79 17 96 O9 O7 38 22. 2 9. 75 63. 3 1. 42 1. 71 1. 05 1. 45 12 O0 0 21. 1 10. 12 62. 3 1. 69 1. 66 1. 8O 6 1. 15 2. 95 14 6 (l0 0 In this system a lower limit for good recovery j40 From the standpoint of corrosion glass howexists at 1.45% alkaline earth.

When both alkali and alkaline earth (lime) are added,'intermediate limits exist as illustrated by the following compositions.

ever, the. higher iron oxide is even more harmful than the alkali or alkaline earth otherwise required. I normally prefer therefore to limit Table IV M616 210, 610. 141.0. F9303 TiO C80 MgO R0 1:.0 N610 R10 g if 'f 6 Per cent 22.1 9.56 65.0 r .72 1.76 .00 .67- .10 1s .28 26 22.3 9.42 64.6 1.02 -l.75 .64 .00 .54 .11 .35 .46 0 22.0 9.76 63.2 1.22 1.74 .79 .17 .96 .09 .07 .16 as 2.6 11.08 61.7 1.61 1.77 1.14 .00 1.14 .09 .20. ..20 0

This gives a lower limit of 0.46% alkali when alkaline earth is 0.54%, and only 0.29% when alkaline earth is 1.14%. All four of these limits are consistent with the statement: good recovery of 4 x 12 x 18's is obtained in the above general system when the sum of the alkali and 38% of the alkaline earth is greater than 0.66%. Resist ance to corrosion by glass is greater for the alkali than for the alkaline earth compositions so I normally prefer to keep the alkaline earth low when the block is intended for flux :block use. 1 For use in superstructure or for other purposes out of contact with glass, dolomite can, however, be advantageously used alone or in combination with alka1i,'since it is a far cheaper addition than NazO (added'as soda ash) and also does not give trouble by volatilizaticn.

the iron oxide to that obtained incidentally from the major ingredients, and to adjust the alkali or alkaline earth accordingly.

According to my invention therefore, I obtain 7 refractory castings which are both resistant to corrosion by molten glass and'reooverable free from cracks. This is done by sacrificing a minimum amount of the resistance to corrosion, in.

alkaline earth, in reference to the FezOr' content, V

which will give good recovery of the various sizes of castings desired. Compositions which I have found to be looth resistant and easily recovered free'from cracks'are illustrated in Table Table VI 405974 032000 LQQHWLL 11111 ZrOz SiOz AhOa F610 Tio: CaO Mgo K20 Nazo Melt 70022 2244 9999 61111 t n 7 %%22 I ns Em... M JJ m I A I: P I: S E n n a T "t A e n T mr S ee e Nh h D mm m E m mu T RFF I N U 1 67 5566 m mwflfl M1122 FOREIGN PATENTS THEODORE E. FIELD.

Date

Number Country 800,779 France 1936 REFERENCES CITED The following references are of record in the file of this patent: 

